I am trying to cut out the rebel alliance symbol from a hollow half sphere the size of a golfball to 3D print a golf ball marking stencil. I tried this with tinkercad and already printed it successfully like this: As you can see, I simply extruded an svg and cut out straight down. This works somehow, but of course it is a straight cut, which especially on the outer curve produces quite an angled border compared to the normal of the golf ball, which makes painting the edges harder than it could be.
Now I wanted to bend the symbol along the normals of the sphere curvature using blender and a technique I found here: https://blender.stackexchange.com/a/115121/116795 , bind object with SurfaceDeform modifier to plane, bind Plane with shrinkwrap to Sphere. And it worked, but it somehow looks ragged especially on the inner curvature:
I have played around with the modifier settings like an offset for the shrinkwrap, increasing subdivision, even using the Remesh Modifier to get a different distribution of vertices along the edges. But nothing was really clean.
Basically what I would really want is to extrude an arbitrary svg along the normals of a sphere - in my imagination this should deliver the cleanest result.
So any tips to improve the quality of the edge curvature or pointers to a completely different technique would be highly appreciated, thank you!